Vacuum insulator

ABSTRACT

The vacuum insulator includes an internal structure; a filler for filling empty spaces of the internal structure; and an envelope having an upper envelope composed of a metal layer and a polymer layer formed on the metal layer to surround an upper surface of the internal structure, and a lower envelope composed of a metal layer and a polymer layer formed on the metal layer to surround a lower surface of the internal structure, wherein the metal layer of the upper envelope and the metal layer of the lower envelope being opposite to each other, wherein at an area facing the internal structure in an end of the envelope, the upper envelope and the lower envelope are adhered by a heat adhesion part, and at an area opposite to the internal structure in the end of the envelope, the upper envelope and the lower envelope are adhered by polyurethane.

CROSS-REFERENCE TO RELATED APPLICATIONS

This is a divisional application of U.S. patent application Ser. No.12/709,174 which claims priority under 35 U.S.C. §119(a) to KoreanPatent Application No. 10-2009-0038857 filed in the Republic of Korea onMay 4, 2009, and Korean Patent Application No. 10-2009-0099659 filed inthe Republic of Korea on Oct. 20, 2009. The entire disclosure of U.S.patent application Ser. No. 12/709,174, and Korean Patent ApplicationNos. 10-2009-0038857 and 10-2009-0099659 is hereby incorporated hereinby reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a vacuum insulator for being used asinsulating material for a building or a refrigerator, etc.

2. Background Information

Half of total energy amount consumed by human being is forheating/cooling houses and commercial buildings, and this rate is sameas domestic rate. Considering the fact that supply amount of alternativeenergy is only 1 to 2% of total energy consumption amount and supplyamount for alternative energy is not above 10% even in a long term plan,reducing energy for heating/cooling is the most effective way toovercome this present energy crisis. The reason why much energy isconsumed for heating/cooling is that heat conduction coefficient ofconventional insulators still stays at threshold value of 30 mW/m·K fora last century. An idea for reducing energy consumption to half with theconventional insulating materials is to control the thickness of theinsulating materials. However, in this idea, thickness of insulatingmaterials is too thick to build economic buildings, and it inevitablyrequires breaking down conventional buildings.

Accordingly, a vacuum insulator has been developed as an ultra insulatorcapable of being used as interior and exterior materials of conventionaland new buildings. The vacuum insulator is composed of a porous fillerand an isolation envelope for surrounding the filler. Since the vacuuminsulator removes gas in the envelope and keeps vacuum state in theenvelope for a few years, the vacuum insulator can have a very low heatconduction rate. Since the vacuum insulator has a 10 to 100 timesinsulating efficiency compared to conventional insulating materials, theinsulating effect can be increased by using the vacuum insulator. Sincethe thickness of the insulator compared to conventional insulatingmaterials is decreased, utilization of internal space can be improved.In addition, since the inside of the vacuum insulator is kept vacuum,the convective heat conduction in the inside can be prevented. Here, thevacuum level in the vacuum insulator causes remarkable difference invacuum efficiency, and thus it is important to keep the vacuum level inthe vacuum insulator. Factors of increasing internal pressure andaffecting the vacuum level in the vacuum insulator are gas escape froman internal structure, air infiltration from the envelope, and airinfiltration through the envelope surface or the envelope adhesion part.The most influential one of those factors is the air infiltrationthrough the envelope adhesion part.

In the conventional method, in order to prevent air infiltration throughthe envelope adhesion part, the adhesion part is adhered by heat withLow density polyethylene LDPE film and a Linear low density polyethyleneLLDPE film having a high permeability.

FIG. 1 is a schematic diagram for showing a structure of a vacuuminsulator according to the conventional technique.

As shown in FIG. 1, the vacuum insulator according to the conventionaltechnique comprises an envelope 10, an internal structure 30 and afiller 40. The adhesion part 20 of four edges parts in which a Lowdensity polyethylene film LDPE, an aluminium film, a Linear low densitypolyethylene LLDPE film are stacked, is adhered by heat. This envelope10 prevents air infiltration from the outside.

FIG. 2 a and FIG. 2 b are cross sectional views of showing structures ofthe envelope of the vacuum insulator according to the conventionaltechnique.

FIG. 2 a is a cross sectional view of showing a structure of theenvelope at an area cut along B-B of FIG. 1, and FIG. 2 b is a crosssectional view of showing the structure of the envelope at an area cutalong A-A of FIG. 1. Here, FIG. 2 a is a cross sectional view of theenvelope 10 of FIG. 1, and FIG. 2 b is a cross sectional view of theadhesion part 20 of FIG. 1.

As shown in FIG. 2 a, the envelope of a single film according to theconventional technique is composed of a Polyethylene terephthalate filmPET 11, a Low density polyethylene film LDPE 12, an aluminium film 13,and a Low density polyethylene film LDPE 14 and a Linear low densitypolyethylene film LLDPE 15. Here, since the aluminium film at the middleof the envelope has a low permeability, air permeation from the outsidethrough the envelope surface can be prevented.

As shown in FIG. 2 b, in the adhesion part 20 where two envelops areadhered, the envelope of a single film composed of a Polyethyleneterephthalate film PET 11 a, a Low density polyethylene film LDPE 12 a,an aluminium film 13 a, and a Low density polyethylene film LDPE 14 aand a Linear low density polyethylene film LLDPE 15 a is adhered withanother single layer envelope composed of a Linear low densitypolyethylene film LLDPE 15 b, a Low density polyethylene film LDPE 14 b,an aluminium film 13 b, a Low density polyethylene film LDPE 12 b and aPolyethylene terephthalate film PET 11 b.

Here, the two envelopes are adhered by heat the Low density polyethylenefilm LDPE 14 a, 14 b and the Linear low density polyethylene film LLDPE15 a, 15 b. However, the Low density polyethylene film LDPE 14 a, 14 band the Linear low density polyethylene film LLDPE 15 a, 15 b have aproblem of making air infiltration easy through the adhesion partbecause of its high air permeability.

In addition, since vacuum level in the vacuum insulator is not kept dueto the reasons, insulating efficiency can be reduced remarkably. Inaddition, since insulating efficiency of the vacuum insulator is reducedremarkably, the vacuum insulator can not perform its role.

SUMMARY OF THE INVENTION

The present invention is conceived to solve the aforementioned problems.Accordingly, the present invention provides a vacuum insulator, in whichair infiltration through an adhesion part of the envelope can be reducedand vacuum maintenance performance can be improved, compared to aconventional case of adhering the envelope by a heat, by adhering ametal layer of an upper envelope and a metal layer of a lower envelopeby polyurethane.

In addition, the present invention provides a vacuum insulator, in whichair infiltration from the outside through a surface of the envelope canbe prevented effectively and the adhesion by urethane can be easy, byusing the envelope comprising a metal layer.

In addition, the present invention provides a vacuum insulator, in whichvacuum maintenance performance of the vacuum insulator can be improved,by adhering the metal layer of the upper envelope and the metal layer ofthe lower envelope by heat between which a film composed of the LDPE andthe LLDPE is inserted, only in a certain area along outlines of theupper envelope and the lower envelope.

In addition, the present invention provides a vacuum insulator, in whichany additional shield against radiation is not necessary to be installedand the manufacture process can be easy and convenient, by the metallayer having a high reflection rate and performing as a shield againstradiation, in the lowest layer of the envelope.

In addition, the present invention provides a vacuum insulator, by whichgaps made of the heat adhesion part between the metal layers and themetal layer can be decreased, and air infiltration through the end ofthe envelope which is a factor affecting the vacuum level by increasinginternal pressure thereof can be reduced, and reduction of theinsulating efficiency can be prevented by keeping a vacuum level of thevacuum insulator, by inserting a metal layer to a heat adhesion part foradhering ends of the envelopes by heat.

In addition, the present invention also provides a vacuum insulator, bywhich air infiltration through the end of the envelope which is a factoraffecting the vacuum level by increasing internal pressure thereof canbe reduced, and reduction of the insulating efficiency can be preventedby keeping a vacuum level of the vacuum insulator, by adhering an areafacing the internal structure in an end of the envelope of the vacuuminsulator by a heat adhesion part, and adhering a area opposite to theinternal structure by a polyurethane.

In addition, the present invention provides a vacuum insulator, by whichgaps made of the heat adhesion part between the metal layers and themetal layer can be decreased at an area facing the internal structure,and the metal layers can be adhered with very thin thickness at an areaopposite to the internal structure, and air infiltration through the endof the envelope which is a factor affecting the vacuum level byincreasing internal pressure thereof can be reduced, and reduction ofthe insulating efficiency can be prevented by keeping a vacuum level ofthe vacuum insulator, by adhering an area facing the internal structurein an end of the envelope of the vacuum insulator by a heat adhesionpart, and adhering a area opposite to the internal structure by apolyurethane, and inserting a metal layer to a adhesion part.

A vacuum insulator related to claim 1 includes: an internal structure; afiller for filling empty spaces of the internal structure; and anenvelope having an upper envelope composed of a metal layer and apolymer layer formed on the metal layer to surround an upper surface ofthe internal structure, and a lower envelope formed of a metal layer anda polymer layer formed on the metal layer to surround a lower surface ofthe internal structure, wherein the metal layer of the upper envelopeand the metal layer of the lower envelope are opposite to each other,wherein in a certain area along outlines of the upper envelope and thelower envelope, the metal layer of the upper envelope and the metallayer of the lower envelope are adhered by polyurethane, and in an areaexcluding the certain area, the metal layer of the upper envelope andthe metal layer of the lower envelope between which a film composed of aLow density polyethylene LDPE and a LinearLow density polyethylene LLDPEis inserted, are adhered by heat.

Consequently, according to the apparatus for the vacuum insulatorrelated to claim 1, since the metal layer of the upper envelope and themetal layer of the lower envelope are adhered by polyurethane, and airinfiltration through the adhesion part can be reduced and vacuummaintenance performance can be improved, compared to a conventional caseof adhering the envelope by a heat. In addition, since the envelopeincludes the metal layer, air infiltration from the outside through thesurface of the envelope can be prevented efficiently and an adhesion canbe easily performed by urethane. In addition, since only in an areaexcluding the certain area, the metal layer of the upper envelope andthe metal layer of the lower envelope between which the film composed ofthe LDPE and the LLDPE is inserted, are adhered by heat, the vacuummaintenance performance of the vacuum insulator can be improved.

The vacuum insulator related to claim 2 is the vacuum insulator as setforth in claim 1 wherein the polymer layer is formed by stacking atleast one of polymer films.

Consequently, according to the vacuum insulator related to claim 2,since the polymer layer is formed by stacking at least one of polymerfilms, the lower metal layer can be protected from breakage and airinfiltration into the envelope can be effectively prevented.

A vacuum insulator related to claim 3 includes: an internal structure; afiller for filling empty spaces of the internal structure; and anenvelope having an upper envelope composed of a metal layer and apolymer layer formed on the metal layer to surround an upper surface ofthe internal structure, and a lower envelope composed of a metal layerand a polymer layer formed on the metal layer to surround a lowersurface of the internal structure, wherein the metal layer of the upperenvelope and the metal layer of the lower envelope are opposite to eachother, and the upper envelope and the lower envelope are adhered by aheat adhesion part at an end of the envelope, and a metal layer isinserted to the heat adhesion part in order to reduce air infiltrationthrough the heat adhesion part.

Consequently, according to the vacuum insulator related to claim 3,since a metal layer is inserted to a heat adhesion part for adheringends of the envelopes by heat, gaps made of the heat adhesion partbetween the metal layers and the metal layer can be decreased, and airinfiltration through the end of the envelope which is a factor affectingthe vacuum level by increasing internal pressure thereof can be reduced,and reduction of the insulating efficiency can be prevented by keeping avacuum level of the vacuum insulator.

A vacuum insulator related to claim 4 includes: an internal structure; afiller for filling empty spaces of the internal structure; and anenvelope having an upper envelope composed of a metal layer and apolymer layer formed on the metal layer to surround an upper surface ofthe internal structure, and a lower envelope composed of a metal layerand a polymer layer formed on the metal layer to surround a lowersurface of the internal structure, wherein the metal layer of the upperenvelope and the metal layer of the lower envelope are opposite to eachother, wherein at an area facing the internal structure in an end of theenvelope, the upper envelope and the lower envelope are adhered by aheat adhesion part, and at a area opposite to the internal structure inthe end of the envelope the upper envelope and the lower envelope areadhered by polyurethane.

Consequently, according to the vacuum insulator related to claim 4,since an area facing the internal structure in an end of the envelope ofthe vacuum insulator is adhered by a heat adhesion part, and a areaopposite to the internal structure is adhered by a polyurethane, airinfiltration through the end of the envelope which is a factor affectingthe vacuum level by increasing internal pressure thereof can be reduced,and reduction of the insulating efficiency can be prevented by keeping avacuum level of the vacuum insulator.

A vacuum insulator related to claim 5 includes: an internal structure; afiller for filling empty spaces of the internal structure; and anenvelope having an upper envelope composed of a metal layer and apolymer layer formed on the metal layer to surround an upper surface ofthe internal structure, and a lower envelope composed of a metal layerand a polymer layer formed on the metal layer to surround a lowersurface of the internal structure, wherein the metal layer of the upperenvelope and the metal layer of the lower envelope are opposite to eachother, wherein at an area facing the internal structure in an end of theenvelope, the upper envelope and the lower envelope are adhered by aheat adhesion part, and at a area opposite to the internal structure inthe end of the envelope, the upper envelope and the lower envelope areadhered by polyurethane, and a metal layer is inserted to the heatadhesion part in order to reduce air infiltration through the heatadhesion part.

Consequently, according to the vacuum insulator related to claim 5,since an area facing the internal structure in an end of the envelope ofthe vacuum insulator is adhered by a heat adhesion part, and an areaopposite to the internal structure is adhered by a polyurethane, and ametal layer is inserted to a adhesion part, gaps made of the heatadhesion part between the metal layers and the metal layer can bedecreased at an area facing the internal structure, and the metal layerscan be adhered with very thin thickness at an area opposite to theinternal structure, and air infiltration through the end of the envelopewhich is a factor affecting the vacuum level by increasing internalpressure thereof can be reduced, and reduction of the insulatingefficiency can be prevented by keeping a vacuum level of the vacuuminsulator.

According to the present invention configured as described above, sincea metal layer of an upper envelope and a metal layer of a lower envelopeare adhered by polyurethane, air infiltration through an adhesion partof the envelope can be reduced and vacuum maintenance performance can beimproved, compared to a conventional case of adhering the envelope by aheat.

According to the present invention, since the envelope comprises a metallayer, air infiltration from the outside through a surface of theenvelope can be prevented effectively and the adhesion by urethane canbe easy.

According to the present invention, since the metal layer of the upperenvelope and the metal layer of the lower envelope by heat between whicha film composed of the LDPE and the LLDPE is inserted, are adhered,vacuum maintenance performance of the vacuum insulator can be improved.

According to the present invention, since the metal layer having a highreflection rate, performs as a shield against radiation, in the lowestlayer of the envelope, any additional shield against radiation is notnecessary to be installed and the manufacture process can be easy andconvenient.

According to the present invention, since a metal layer is inserted to aheat adhesion part for adhering ends of the envelopes by heat, gaps madeof the heat adhesion part between the metal layers and the metal layercan be decreased, and air infiltration through the end of the envelopewhich is a factor affecting the vacuum level by increasing internalpressure thereof can be reduced, and reduction of the insulatingefficiency can be prevented by keeping a vacuum level of the vacuuminsulator.

According to the present invention, since an area facing the internalstructure in an end of the envelope of the vacuum insulator is adheredby a heat adhesion part, and an area opposite to the internal structureis adhered by a polyurethane, an area facing the internal structure canbe adhered by adhesion part, and an area opposite to the internalstructure can be adhered by a polyurethane with very thin thickness, airinfiltration through the end of the envelope which is a factor affectingthe vacuum level by increasing internal pressure thereof can be reduced,and reduction of the insulating efficiency can be prevented by keeping avacuum level of the vacuum insulator.

According to the present invention, since an area facing the internalstructure in an end of the envelope of the vacuum insulator is adheredby a heat adhesion part, and an area opposite to the internal structureis adhered by a polyurethane, and a metal layer is inserted to aadhesion part, gaps made of the heat adhesion part between the metallayers and the metal layer can be decreased at an area facing theinternal structure, and the metal layers can be adhered with very thinthickness at an area opposite to the internal structure, and airinfiltration through the end of the envelope which is a factor affectingthe vacuum level by increasing internal pressure thereof can be reduced,and reduction of the insulating efficiency can be prevented by keeping avacuum level of the vacuum insulator.

The objects, constructions and effects of the present invention areincluded in the following embodiments and drawings. The advantages,features, and achieving methods of the present invention will be moreapparent from the following detailed description in conjunction withembodiments and the accompanying drawings. The same reference numeralsare used throughout the drawings to refer to the same or like parts.

BRIEF DESCRIPTION OF THE DRAWINGS

The above and other features and advantages of the present inventionwill become more apparent to those of ordinary skill in the art bydescribing in detail preferred embodiments thereof with reference to theattached drawings, in which:

FIG. 1 is a schematic diagram for showing the structure of the vacuuminsulator relating to the conventional technique;

FIG. 2 a is a cross sectional view of showing the structure of theenvelope at an area cut along B-B of FIG. 1, and FIG. 2 b is a crosssectional view of showing the structure of the envelope at an area cutalong A-A of FIG. 1;

FIG. 3 is a top view for showing the structure of the vacuum insulatoraccording to a first embodiment of the present invention;

FIG. 4 is a cross sectional view of showing an internal structure of thevacuum insulator according to the first embodiment of the presentinvention;

FIG. 5 is a cross sectional view of the envelope of the vacuum insulatoraccording to the first embodiment of the present invention (along B-B inFIG. 4);

FIG. 6 is a cross sectional view of the envelope of the vacuum insulatoraccording to the first embodiment of the present invention (along A-A inFIG. 4);

FIG. 7 is a cross sectional view of showing a structure of the vacuuminsulator according to the second to the fourth embodiment of thepresent invention;

FIG. 8 is a cross sectional view of the end of the envelope of thevacuum insulator according to a second embodiment of the presentinvention (along A-A in FIG. 7);

FIG. 9 is a cross sectional view of an end of the envelope of the vacuuminsulator according to a third embodiment of the present invention(along A-A in FIG. 7); and

FIG. 10 is a cross sectional view of an end of the envelope of thevacuum insulator according to a fourth embodiment of the presentinvention (along A-A in FIG. 7).

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Above all, a theoretical background relating to the present invention isdescribed in detail.

First Embodiment

FIG. 3 is a top view for showing the structure of the vacuum insulatoraccording to a first embodiment of the present invention. FIG. 4 is across sectional view of showing an internal structure of the vacuuminsulator according to the first embodiment of the present invention.

As shown in FIGS. 3 and 4, the vacuum insulator of the first embodimentof the present invention includes an internal structure 300, a filler200 for filling spaces of the internal structure 300, and an envelope100 for surrounding the internal structure 200.

The internal structure 300 is designed to have minimal heat transmissionto endure the atmospheric pressure. In addition, the internal structure300 is preferably formed of material having high ratio of a tensilestrength to heat conduction coefficient. For example, polymer is used asa result of considering tensile strength, heat conduction rate andmanufacture factors. More specifically, Polycarbonate or Polyimide ispreferably used among polymers, which has high ratio of a tensilestrength to heat conduction coefficient.

The filler 200 is a material for filling empty spaces of the internalstructure 300 to keep efficiency of the vacuum insulator even in a lowvacuum level. The smaller the filler 200 is, the better the performanceof the filler 200 is. In addition, the filler 200 is a porous filler forreducing heat conduction by gas, and may be made of silica powder,pearlite powder, glass fiber, wool and aerogel, etc.

The envelope 100 has an upper envelope and a lower envelope. Theenvelope 100 is for preventing air infiltration from the outside, and itis preferable to use a film made of material keeping vacuum state for along time. The envelope is composed of a metal layer and a polymerlayer. The polymer layer is formed by stacking at least one of polymerfilms.

As shown in FIG. 3, in view of the upper side of the vacuum insulatoraccording to the first embodiment, an envelope 120 includes an adhesionpart 130 and a heat adhesion part 140 along an outline of the envelope120.

The adhesion part 130 is a certain area along outlines of the upperenvelope the upper envelope and the lower envelope. In the certain areaalong outlines of the upper envelope and the lower envelope, the metallayer of the upper envelope and the metal layer of the lower envelopeare adhered by polyurethane of low permeability.

The heat adhesion part 140 is an area excluding the certain area alongoutlines of the upper envelope the upper envelope and the lowerenvelope. In the area excluding the certain area, the metal layer of theupper envelope and the metal layer of the lower envelope between which afilm (refer to a following description of FIG. 6) of high permeationcomposed of a Low density polyethylene LDPE and a LinearLow densitypolyethylene LLDPE is inserted, are adhered by heat.

The vacuum insulator is formed in a pouch shape by adhering the metallayers of the certain area by Urethane. Then, air in the envelope 120 isdischarged through the heat adhesion part 140, and the heat adhesionpart 140 is adhered by heat. Here, a reason for adhering only the heatadhesion part 140 by heat is that, in case of using Urethane, it takes alot of time (about 24 hours) to dry Urethane, and thus it is difficultto keep vacuum state in the vacuum insulator. Accordingly, in the vacuuminsulator according to the present invention, since only the heatadhesion part 140 is rapidly adhered by heat, the vacuum state insidethe vacuum insulator can be easily kept.

FIG. 5 is a cross sectional view of the envelope of the vacuum insulatoraccording to the first embodiment of the present invention (along B-B inFIG. 4), and FIG. 6 is a cross sectional view of the envelope of thevacuum insulator according to the first embodiment of the presentinvention (along A-A in FIG. 4). FIG. 5 is a cross sectional view of theenvelope 130 of FIG. 3, and FIG. 6 is a cross sectional view of thejunction part 140 of FIG. 3. Since the envelope for the vacuum insulatorcovers an external side of the vacuum insulator to reduce airinfiltration into the vacuum insulator, vacuum state thereof can bekept. Specific structure of the envelope will be described with respectto FIG. 5 and FIG. 6. Meanwhile, in FIG. 5 and FIG. 6, there is at leastone of polymer films forming a polymer layer of the envelope for thevacuum insulator, and a polyethylene terephthalate film and a lowdensity polyethylene film will be described as an example.

As shown in FIG. 5, the envelope for the vacuum insulator according tothe first embodiment of the present invention is composed of a polymerlayer 131, 132 and a metal layer 133.

The polymer layer 131, 132 is formed by stacking at least one of polymerfilms. For example, the polymer layer 131, 132 formed by stacking apolyethylene terephthalate film 131 and a low density polyethylene film132. In the present invention, the polymer layer 131,132 is formed bystacking the PET Polyethylene terephthalate film 131 and the LDPE Lowdensity polyethylene 132 as an example, and however the polymer layer131, 132 may be formed by stacking a polymer film such as LLDPELinear-Low density polyethylene film in addition to the PET film 131 andthe LDPE film 132. Also, the polymer layer 131, 132 may be composed ofthe other polymer film except for PET film, the LDPE film and LLDPEfilm.

The metal layer 133 is formed of a metal having a high reflection rateto perform as a shield against radiation. The metal having a highreflection rate may be aluminum or SUS, etc. Accordingly, in the presentinvention, since the vacuum insulator does not need any additionalshield against radiation, it can be made easily.

As shown in FIG. 6, the adhesion part of the vacuum insulator accordingto the first embodiment of the present invention has an upper envelope131 a, 132 a, 133 a, a lower envelope 131 b, 132 b, 133 b and anadhesion layer 134 therebetween. In other words, the envelopes formed ina single-layer film type of FIG. 5 are contacted with each other in theupward and downward directions in FIG. 6. In addition, the adhesionlayer 134 is applied with polyurethane in order to adhere the metallayer 133 a of the upper envelope 131 a, 132 a, 133 a, and the metallayer 133 b of the lower envelope 131 b, 132 b, 133 b.

The upper envelope 131 a, 132 a, 133 a is composed of a metal layer 133a and a polymer layer 131 a, 132 a formed on the metal layer 133 a. Themetal layer 133 a is formed of aluminium. In addition, the metal layer133 a may be formed of the other metal except for aluminium. The polymerlayer 131 a, 132 a may be formed by stacking at least one of polymerfilms. For example, the polymer film may be a polyethylene terephthalatePET film, a low density polyethylene LDPE film, a Linear-Lowdensitypolyethylene LLDPE film, etc.

The lower envelope 131 b, 132 b, 133 b is composed of a metal layer 133b and a polymer layer 131 b, 132 b formed on the metal layer 133 b. Themetal layer 133 b is formed of aluminium. In addition, the metal layer133 a may be formed of the other metal except for aluminium. The polymerlayer 131 b, 132 b may be formed by stacking at least one of polymerfilms. For example, the polymer film may be a polyethylene terephthalatePET film, a low density polyethylene LDPE film, a Linear-Lowdensitypolyethylene LLDPE film, etc.

The adhesion layer 134 is made of polyurethane, and the metal layer 133a of the upper envelope 131 a, 132 a, 133 a and the metal layer 133 b ofthe upper envelope 131 b, 132 b, 133 b are adhered with each other.

Since air infiltration efficiency of the adhesion method of using thejunction layer 134 made of polyurethane is lower than that of theconventional method of adhering the LDPE film and the LLDPE film byheat, the envelope having better vacuum maintenance performance than theconventional envelope can be provided.

For example, each permeability for nitrogen and oxygen gas of thepolyurethane is as follows.

k _(N2)=0.00975×10⁻¹³ cm³cm/cm²sPa,k _(O2)=0.0645×10⁻¹³ cm³cm/cm²sPa

In addition, each permeability for nitrogen and oxygen gas of the Lowdensity polyethylene LDPE is as follows.

k _(N2)=0.73×10⁻¹³ cm³cm/cm²sPa,k _(O2)=2.2×10⁻¹³ cm³cm/cm²sPa

(Ref. J. Brandrup, E. H. Immergut and E. A. Grulke, PolymerHandbook-Permeability and Diffusion Data 4^(th) ed., Wiley, New York,1999, pp. vi. 545-560).

In the vacuum insulator and the envelope of the vacuum insulatoraccording to the first embodiment of the present invention, since ametal layer of an upper envelope and a metal layer of a lower envelopeis adhered by polyurethane, air infiltration through an adhesion part ofthe envelope can be reduced and vacuum maintenance performance can beimproved, compared to a conventional case of adhering the envelope by aheat. In addition, according to the present invention, since theenvelope comprises a metal layer, air infiltration from the outsidethrough a surface of the envelope can be prevented effectively and theadhesion by urethane can be easy. In addition, according to the presentinvention, since the metal layer of the upper envelope and the metallayer of the lower envelope by heat between which a film composed of theLDPE and the LLDPE is inserted, are adhered only in an area excludingthe certain area along the outlines of the upper envelope and the lowerenvelope, vacuum maintenance performance of the vacuum insulator can beimproved In addition, according to the present invention, since themetal layer having a high reflection rate, performs as a shield againstradiation, in the lowest layer of the envelope, any additional shieldagainst radiation is not necessary to be installed and the manufactureprocess can be easy and convenient.

FIG. 7 is a cross sectional view of showing a structure of the vacuuminsulator according to the second to the fourth embodiment of thepresent invention.

As shown in FIG. 7, the vacuum insulator is composed of an internalstructure 200, a filler 300 and an envelope 100.

The internal structure 200 is preferably designed to have a longest heatconduction passage to minimize heat conduction in order to endure an airpressure. Here, the internal structure 200 may be formed in a multilayer structure having a plural of beams, and may be formed in a simplestructure having not the multi layer.

The filler 300 is a material for filling empty spaces of the internalstructure 200, and prevents heat conduction by gas in the vacuuminsulator. As for the filler 300, there are materials such as silicapowder, pearlite powder, glass fiber, wool and aerogel, etc.

The envelope 100 surrounds the internal structure 200 to prevent airinfiltration from the outside. Here, the envelope 100 is composed of afilm which is capable of keeping a vacuum level for a long time due toits low gas permeability. The envelope 100 has an upper envelope formedof a metal layer and a polymer layer formed on the metal layer tosurround an upper surface of the internal structure, and a lowerenvelope formed of a metal layer and a polymer layer formed on the metallayer to surround a lower surface of the internal structure. Here, themetal layer is formed of copper Cu or aluminium Al, etc. to reduce airinfiltration from the outside. In addition, the polymer layer is formedby stacking at least one of polymer films. In addition, the metal layerof the upper envelope and the metal layer of the lower envelope areopposite to each other. In the vacuum insulator according to the presentinvention, the polymer layer has a structure in which a Polyethyleneterephthalate film PET and a Lowdensity polyethylene film LDPE arestacked, and however the insulator is not limited to the structure. Thepolymer layer may have a structure in which a polymer film such as aLLDPE Linear-Lowdensity polyethylene film is stacked in addition to thePolyethylene terephthalate film PET and a Lowdensity polyethylene filmLDPE. Also, the polymer layer 131, 132 may be composed of the otherpolymer film except for PET film, the LDPE film and LLDPE film.Meanwhile, the upper envelope and the lower envelope are joined at endsof the envelope.

The envelope is adhered at the end of the envelope. The metal layers ofthe upper envelope and the lower envelope can be adhered by apolyurethane or a heat-adhesion part having a Lowdensity polyethyleneLDPE and a Linear-Lowdensity polyethylene LLDPE. However, since theheat-adhesion part composed of the LDPE and the LLDPE has a high airpermeability to allow relatively much air to be permeated, it isdifficult to keep a vacuum level of the vacuum insulator, and theinsulating efficiency can be reduced remarkably. Accordingly, since ametal layer is inserted to the heat-adhesion part, a thickness of theheat-adhesion part by inserting a metal layer can be reduced and airpermeation through the heat-adhesion part from the outside can bereduced.

Second Embodiment

FIG. 8 is a cross sectional view of the end of the envelope for thevacuum insulator according to a second embodiment according to thepresent invention (along A-A in FIG. 7).

As shown in FIG. 8, in the end of the envelope for the vacuum insulator,the upper envelope A and the lower envelope B are adhered by the heatadhesion part H. In the vacuum insulator according to the presentinvention, since a metal layer 200 is inserted to the heat-adhesion partH to reduce air infiltration through the heat-adhesion part H, a gapbetween the metal layer 113 a of the upper envelope A and the metallayer 113 b of the lower envelope B can be decreased. Here, the upperenvelope A has a structure in which a Polyethylene terephthalate filmPET 111 a, a Low density polyethylene film LDPE 112 a and a metal layer113 a are stacked. The lower envelope B has a structure in which aPolyethylene terephthalate film PET 111 b, a Low density polyethylenefilm LDPE 112 b and a metal layer 113 b are stacked.

In addition, the heat adhesion part H is composed of a Lowdensitypolyethylene LDPE 114 a, 114 b and a Linear-Lowdensity polyethyleneLLDPE film 115.

More specifically, in the end of the envelope of the vacuum insulator,the metal layer 113 a of the upper envelope A and the metal layer 113 bof the lower envelope B are adhered by the heat adhesion part H. Inaddition, since the metal layer 200 is inserted to the heat adhesionpart H, between the metal layer 113 a of the upper envelope A and themetal layer 113 b of the lower envelope B, a thickness of the heatadhesion part H having the LDPE films and the LLDPE film can bedecreased, and air infiltration through the heat adhesion part from theoutside due to a low air permeability of the metal layer 200 can beeffectively prevented. A surface of the metal layer 200 is preferablypositioned between a surface of the metal layer 113 a and a surface ofthe metal layer 113 b. However, in order to maximally decrease thethickness of the heat adhesion part H between the surface of the metallayer 113 a and the surface of the metal layer 113 b, a surface of themetal layer 200 is preferably contacted with the surface of the metallayer 113 a of the upper envelope A and the surface of the metal layer113 b of the lower envelope B.

As shown in FIG. 8, the metal layer 200 may have a circular sectionshape. In addition, although not shown in this figure, the metal layer200 may have a polygonal section shape.

As described above, in the vacuum insulator of the second embodimentaccording to the present invention, in order to reduce air infiltrationthrough the end of the envelope, since the metal layer 200 is insertedto the heat adhesion part H for adhering the ends of the envelopes, gapsformed of the heat adhesion part H between the metal layer 113 a and themetal layer 200 and between the metal layer 113 b and the metal layer200 can be decreased.

Third Embodiment

FIG. 9 is a cross sectional view of an end of the envelope for thevacuum insulator according to a third embodiment of the presentinvention (along A-A in FIG. 7).

As shown in FIG. 9, at an area facing the internal structure in the endof the envelope for the vacuum insulator according to the thirdembodiment of the present invention, the upper envelope A and the lowerenvelope B are adhered by a heat adhesion part H. At a area in the endof the envelope, the upper envelope A and the lower envelope B areadhered by polyurethane 300. The upper envelope A is a portion where aPolyethylene terephthalate film PET 121 a, Low density polyethylene filmLDPE 122 a and a metal layer 123 a are stacked. In addition, the lowerenvelope B is a portion where a Polyethylene terephthalate film PET 121b, a Low density polyethylene film LDPE 122 b and a metal layer 123 bare stacked. In addition, the heat adhesion part H is composed of a LDPELowdensity polyethylene film 124 a, 124 b, and Linear-Lowdensitypolyethylene film LLDPE 125.

More specifically, at the area facing the internal structure of the endof the envelope, the metal layer 123 a of the upper envelope A and themetal layer 123 b of the lower envelope B are adhered by the heatadhesion. In addition, at side area opposite of the internal structurein the end of the envelope, the heat adhesion H composed of Low densitypolyethylene film LDPE 124 a, 124 b and Linear low density polyethyleneLLDPE 125 film is melted to expose the metal layers 123 a 123 b, thenthe metal layers are adhered again by polyurethane 300 with a very thinthickness, having a low air permeability. The heat adhesion H, which iscomposed of the Low density polyethylene film LDPE 124 a, 124 b and theLinear low density polyethylene LLDPE 125 of the area opposite of theinternal structure in the end of the envelope, may be melted and removedby heat or solvents. Since the LDPE Low density polyethylene film andthe LLDPE Linear low density polyethylene are not melted well by thegeneral organic solvents, the LDPE and the LLDPE are melted by heat ofmore than 120° C. or melted by solvents such as a toluene, xylene, andcyclohexane, etc at about 90° C. Since the polyurethane 300 has lowerair infiltration than the adhesion by the heat adhesion part H composedof the LDPE film and the LLDPE film, vacuum maintenance performance canbe more remarkable improved. (Permeability of the Polyurethanek_(N2)=0.00975×10⁻¹³ cm³cm/cm²sPa, k_(O2)=0.0645×10⁻¹³ cm³cm/cm²sPa, andPermeability of the Low density polyethylene LDPE k_(N2)=0.73×10⁻¹³cm³cm/cm²sPa, k_(O2)=2.2×10⁻¹³ cm³cm/cm²sPa) (Ref. J. Brandrup, E. H.Immergut and E. A. Grulke, Polymer Handbook-Permeability and DiffusionData 4^(th) ed., Wiley, New York, 1999, pp. VI. 545-560).

As described above, in the vacuum insulator according to the thirdembodiment of the present invention, in order to reduce air infiltrationfrom the outside through the end of the envelope, the area facing theinternal structure in the end of the envelope of the vacuum insulator isadhered by the heat adhesion part H, and the area opposite to theinternal structure in the end of the envelope of the vacuum insulator isadhered by the polyurethane 300.

Fourth Embodiment

FIG. 10 is a cross sectional view of an end of the envelope for thevacuum insulator according to a fourth embodiment of the presentinvention (along A-A in FIG. 7).

As shown in FIG. 10, in the end of the envelope for the vacuum insulatoraccording to the fourth embodiment of the present invention, the upperenvelope A and the lower envelope B are adhered by the heat adhesionpart at an area facing the internal structure, and the upper envelope Aand the lower envelope B are adhered by the polyurethane 300 at a areaopposite to the internal structure in the end of the envelope of thevacuum insulator. In addition, in order to reduce air infiltrationthrough the heat adhesion part H, a metal layer 200 is inserted to theheat adhesion part H. The upper envelope A is a portion where a PETPolyethylene terephthalate film 131 a, a LDPE Low density polyethylenefilm 132 a, and a metal layer 133 a are stacked. The lower envelope B isa portion where a Polyethylene terephthalate film PET 131 b, a Lowdensity polyethylene film LDPE 132 b, and a metal layer 133 b arestacked. In addition, the heat adhesion part H is composed of aLowdensity polyethylene film LDPE 134 a, 134 b and a Linear-Lowdensitypolyethylene film LLDPE 135.

More specifically, at an area facing the internal structure in the endof the envelope, the metal layer 133 a of the upper envelope A and themetal layer 133 b of the lower envelope B are adhered by the heatadhesion part H. In addition, the metal layer 200 is inserted into theheat adhesion part H, between the metal layer 133 a of the upperenvelope A and the metal layer 133 b of the lower envelope B. In theatmosphere state, at the area opposite to the internal structure in theend of the envelope, the heat adhesion H composed of Low densitypolyethylene film LDPE 134 a, 134 b and Linear low density polyethyleneLLDPE 135 film is melted to expose the metal layers 133 a 133 b, thenthe metal layers are adhered again by polyurethane 300 with a very thinthickness, having a low air permeability. Accordingly, air infiltrationthrough the surface of the envelope from the outside can be prevented bythe metal layer 200 which is located in the middle of the area facingthe internal structure of the end of the envelope, and air infiltrationthrough the heat adhesion part H can be effectively prevented bypolyurethane 300 and the metal layer 200. A surface of the metal layer200 is preferably positioned between a surface of the metal layer 133 aand a surface of the metal layer 133 b. However, in order to maximallydecrease the thickness of the heat adhesion part H between the surfaceof the metal layer 133 a and the surface of the metal layer 133 b, asurface of the metal layer 200 is preferably contacted with the surfaceof the metal layer 133 a of the upper envelope A and the surface of themetal layer 133 b of the lower envelope B.

As shown in FIG. 10, the metal layer 200 may have a circular sectionshape. In addition, although not shown in this figure, the metal layer200 may have a polygonal section shape.

As described above, in the vacuum insulator according to the fourthembodiment of the present invention, in order to reduce air infiltrationfrom the outside through the end of the envelope, since the area facingthe internal structure in the end of the envelope of the vacuuminsulator is adhered by the heat adhesion part H, and the area oppositeto the internal structure in the end of the envelope of the vacuuminsulator is adhered by the polyurethane 300, and the metal layer 200 isinserted to the heat adhesion par H, a gab formed of the heat adhesionpart H between the metal layers 133 a, 133 b and the metal layer 200 canbe decreased.

Accordingly, since the vacuum insulator according to the presentinvention has a 10 to 100 times less effective heat conductioncoefficient than a conventional insulating material, internal spaces ofa refrigerator or a building that must be insulated can be insulatedeffectively. In addition, with the vacuum insulator according to thepresent invention, since the thickness of the insulator is reduced, theinternal spaces can be used more effectively. In addition, since thevacuum insulator according to the present invention has high vacuummaintenance performance, the vacuum insulating efficiency can be keptfor a longer time.

As described above, a technical composition of the present invention isto be understood that one skilled in the art is not to modify atechnical idea or an essential feature of the present invention but totake effect as the other concrete embodiments.

Therefore, it is to be understood that embodiments described above arenot qualifying but exemplary in all points. Also, the scope of thepresent invention will be included in the following claims than abovedetail explanation, and it is to be analyzed that the meaning and scopeof the claims and all changes deducted from equivalent arrangements ormodifications included within the scope of the present invention.

1. A vacuum insulator comprising: an internal structure; a filler forfilling empty spaces of the internal structure; and an envelope havingan upper envelope composed of a metal layer and a polymer layer formedon the metal layer to surround an upper surface of the internalstructure, and a lower envelope composed of a metal layer and a polymerlayer formed on the metal layer to surround a lower surface of theinternal structure, wherein the metal layer of the upper envelope andthe metal layer of the lower envelope are opposite to each other,wherein in a certain area along outlines of the upper envelope and thelower envelope, the metal layer of the upper envelope and the metallayer of the lower envelope are adhered by polyurethane, and in an areaexcluding the certain area, the metal layer of the upper envelope andthe metal layer of the lower envelope between which a film composed of aLow density polyethylene LDPE and a LinearLow density polyethylene LLDPEis inserted, are adhered by heat.
 2. The vacuum insulator as set forthin claim 1, wherein the polymer layer is formed by stacking at least oneof polymer films.
 3. A vacuum insulator comprising: an internalstructure; a filler for filling empty spaces of the internal structure;and an envelope having an upper envelope composed of a metal layer and apolymer layer formed on the metal layer to surround an upper surface ofthe internal structure, and a lower envelope composed of a metal layerand a polymer layer formed on the metal layer to surround a lowersurface of the internal structure, wherein the metal layer of the upperenvelope and the metal layer of the lower envelope being opposite toeach other, wherein at an area facing the internal structure in an endof the envelope, the upper envelope and the lower envelope are adheredby a heat adhesion part, and at a area opposite to the internalstructure in the end of the envelope, the upper envelope and the lowerenvelope are adhered by polyurethane.